Conveyor belt and module with wear pads

ABSTRACT

A plastic modular conveyor belt constructed of belt modules with wear pads. The belt is supported in the carryway of a conveyor atop linear wearstrips along which the belt&#39;s wear pads slide as the belt advances.

BACKGROUND

The invention relates generally to power-driven conveyors and in particular to modular plastic conveyor belts.

Modular plastic conveyor belts constructed of rows of plastic belt modules joined together end to end at hinge joints are used to convey products in many industrial applications. The belts are supported in product carryways by wearstrips, typically made of UHMW. As the belts ride along the wearstrips, sliding friction between the undersides of the belts and the wearstrips causes the belts to wear. Excessive wear weakens the belt and shortens its effective life.

SUMMARY

One version of a conveyor belt module embodying features of the invention comprises a module body that extends in length from a first end to a second end, in width from a first side to a second side, and in thickness from a top side to a bottom side. First hinge elements are spaced apart laterally along the first side of the module body, and second hinge elements are spaced apart laterally along the second side of the module body. Drive faces extend laterally along the bottom side of the module body. One or more wear pads on the bottom side of the module body are laterally offset from the drive faces. The wear pads each have a wear surface at the bottom side. The area of the wear surface of each of the wear pads is greater than the area of any of the first and second hinge elements at the bottom side.

Another version of a conveyor belt module comprises a module body that extends in length from a first end to a second end, in width from a first side to a second side, and in thickness from a top side to a bottom side. First hinge elements are spaced apart laterally along the first side of the module body, and second hinge elements are spaced apart laterally along the second side of the module body. Drive faces extend laterally along the bottom side of the module body. Wear pads on the bottom side of the module body are laterally offset from the drive faces. The wear pads each have a wear surface at the bottom side made of a different material from the rest of the module body.

In another aspect a conveyor embodying features of the invention comprises a modular conveyor belt constructed of a series of rows of one or more belt modules hingedly connected end to end at hinge joints between consecutive rows. At least some of the rows include drive faces that extend laterally along a bottom side of the modular conveyor belt and wear pads on the bottom side of the modular conveyor belt laterally offset from the drive faces. The wear pads each have a wear surface at the bottom side of the modular conveyor belt. An upper carryway includes wearstrips spaced apart across the width of the carryway. The wearstrips extend linearly along the length of the carryway to support the modular conveyor belt. A drive element engages the drive faces to drive the modular conveyor belt in a direction of belt travel along the carryway. The wear pads on the bottom side of the modular conveyor belt are arranged in columns aligned with the wearstrips so that the wear surfaces ride on the wearstrips as the modular conveyor belt is driven in the direction of belt travel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a plastic conveyor belt module embodying features of the invention including a wear pad.

FIG. 2 is a bottom plan view of the module of FIG. 1.

FIG. 3 is an isometric view of the bottom sides of two modules as in FIG. 2 joined together.

FIG. 4 is an oblique view of the top sides of the modules of FIG. 3 atop wearstrips.

FIG. 5 is a side elevation view of a modular plastic belt conveyor constructed of modules as in FIG. 1.

FIG. 6 is a side elevation view of a module as in FIG. 1 in which the wear surface is made of a different material from the rest of the module.

FIG. 7 is an exploded side elevation view of a module as in FIG. 1 with a detachable wear surface.

FIG. 8 is a front elevation cross section of a wear strip supporting a wear pad as in FIG. 4 in which the wear pad has guides.

FIG. 9 is an axonometric view of the bottom side of another version of a conveyor belt module embodying features of the invention.

FIG. 10 is a front elevation view of a belt module as in FIG. 9 supported on wearstrips.

FIG. 11 is an enlarged bottom plan view of the outer side of a module as in FIG. 2 partly cut away to show a wear indicator.

FIG. 12 is a bottom plan view of a wear pad as in FIG. 1 with a grooved bottom with a wear indicator.

FIGS. 13A and 13B are bottom and top isometric views of a version of a belt edge module embodying features of the invention.

FIGS. 14A and 14B are bottom and top axonometric views of another version of an edge module embodying features of the invention.

DETAILED DESCRIPTION

FIGS. 1 and 2 are top and bottom views of a conveyor belt module embodying features of the invention. The module 20 is a plastic belt module molded out of a thermoplastic polymer, such as polyethylene, polypropylene, acetal, or a composite polymer. The module body extends in length from a first end 22 to a second end 23, in width from a first side 24 to a second side 25, and in thickness from a top side 26 to a bottom side 27. The top side 26 has a conveying surface 21, and the bottom side 27 is the drive side. A plurality of first hinge elements 28 are spaced apart laterally across the width of the module body 20 aligned along the first end 22. A plurality of second hinge elements 29 are spaced apart laterally aligned along the second end 23 of the module body 20. In this version the first and second hinge elements are the same width. But their widths could differ. The first hinge elements 28 are laterally offset from the second hinge elements 29 to facilitate the construction of a conveyor belt from the modules 20.

The belt module 20 shown in FIGS. 1 and 2 has three wear pads: two outside wear pads 30 and an interior wear pad 32. Of course, a module could have more than one interior wear pad, such as in the case of a wider belt module. Or a small module, such as an edge module, could have only a single wear pad. The wear pads 30, 32 have a wear surface 34 at the bottom side 27 of the module body 20. In this version the wear surface 34 is a flat closed surface. But in other versions the wear surface 34 could be interrupted by holes, slits, or other openings that extend through the thickness of the wear pads to provide passages for airflow or drainage, for example. The interior wear pad 32 includes a pad hinge element 36 at the first end 22 of the module 20. The pad hinge element 36 is aligned with the first hinge elements 28 but is distinguished from the first hinge elements by providing a continuation of the wear pad's wear surface 34 at the module's bottom side 27 and of the conveying surface 21 at the module's top side 26. In this version the lateral extent and the area of the wear surface 34 of each of the wear pads 30, 32 are greater than the lateral extent and the bottom area of any of the first and second hinge elements 28, 29 and of any other individual structural elements on the bottom side 27 of the module body 20, other than the pad hinge element 36. The lateral extent of the pad hinge element 36 is at least as wide as the wear surface 34.

Drive bars 38 are laterally elongated along the bottom side 27 of the module body 20. The drive bars 38 form drive faces 40, 41 on one or both sides that can receive a drive force from a drive sprocket. In the depicted version the drive bars 38 are centrally located midway between the first and second ends 22, 23 of the module body 20. But they could be located closer to one of the ends than to the other. Or, instead of being formed on drive bars, the drive faces could be formed on the leading or training walls of drive pockets at the bottom side of the module. The drive bars 38 shown in FIG. 2, which extend laterally from one of the wear pads 30 to another 32, are laterally offset from the wear pads 30, 32. And the drive bars 38 extend downward to the same level as the wear surfaces 34 of the wear pads 30, 32 in this version, in which that level is the bottom-most level of the module. But the drive bars 38 could terminate inward of the wear surfaces 34. Recessed regions 42 at the bottom side 27 between the drive bars 38 and the hinge elements 28, 29 permit access to drive-sprocket teeth to engage the drive faces 40, 41 of the drive bars. End walls 43 of the recessed regions 42 formed by the wear pads 30, 32 limit the lateral wander of a conveyor belt constructed of the modules 20 by confining an axially fixed sprocket to the recessed region to provide belt tracking.

Consecutive conveyor belt modules 20 are connected end to end as shown in FIG. 3 to form a conveyor belt. The first hinge elements 28 and the pad hinge elements 36 interleave with the second hinge elements 29 of a consecutive module 20. In this version, the interleaved hinge elements 28, 29, 36 have aligned openings 44 that receive a hinge rod to form a hinge joint 46 connecting consecutive rows of modules. Spaces 48 between consecutive hinge elements 28, 29, 36 are slightly wider than the hinge elements to receive the hinge elements of the connected row of belt modules. When the modules are connected, the wear pads 30, 32 are arranged in laterally spaced columns 50 that extend along the length of the belt.

As shown in FIG. 3, the columns of wear pads 30, 32 align with and ride on linear wearstrips 52 that extend along the length of the upper conveyor carryway. The wearstrips 52 support the belt in the carryway and provide a sliding surface along which the wear surfaces of the wear pads ride as the belt is driven in a direction of belt travel 54. Thus, the wear pads 30, 32 are the only part of the belt in contact with the wearstrips 52.

An endless conveyor belt loop constructed of linked conveyor belt modules as in FIGS. 1-4 is shown in a conveyor 55 in FIG. 5. The belt 56 is trained around drive and idle sprockets 58, 59. Teeth on the sprockets engage the drive faces of the modules to drive the belt 56 in the direction of belt travel 54. The belt 56 is shown supported by wearstrips 52 on the upper carryway 50. The belt 56 returns from the drive sprockets 58 to the idle sprockets 59 along a lower returnway 61. Each belt row 62 may include one or more belt modules 20 as in FIGS. 1-4, including laterally shortened versions of those modules in a bricklaid belt pattern.

Because the wear pads slide on the wearstrips, they are subjected to greater frictional wear than the rest of the module body. FIG. 6 shows a wear pad 64 whose bottom wear surface 66 is made of a wear-resistant material, such as nylon, acetal, PEEK, and UHMW, permanently fastened to the module body 68 by overmolding, co-molding, ultrasonic welding, gluing, or mechanical attachment, for example. The wear-resistant material may be chosen for its durability or its low-friction properties and may allow the wearstrips to be made of stainless steel. The rest of the module body 68 is made of a different thermoplastic material such as polyethylene, polypropylene, acetal, or other polymeric materials conventionally used to make plastic conveyor belt modules.

A detachable wear surface 70 is shown in FIG. 7. The wear surface 70 has attachment elements in the form of expandable tabs 72 that mate with attachment elements in the form of receptacles 74. In this example the tabs 72 snap into place in the receptacles 74. But any sort of mating attachment elements that releasably fasten in any way may be used to allow for easy replacement of a worn wear surface 70. The wear surface 70 may be made of a wear-resistant material. The module body 76 has a recess 78 at the bottom in which the wear surface 70 resides.

FIG. 8 shows another version of a wear pad. In this version the wear pad 80 has depending guides 82 at each side flanking a wear surface 84 riding along a wearstrip 86. The guides 82 limit lateral wander of the conveyor belt to the width of the slot 88 formed between the two depending guides 82. Thus, the guides 82 provide belt tracking.

Another version of a conveyor belt module is shown in FIG. 9. The belt module 90 has outer wear pads 92 and an inner wear pad 93 whose wear surfaces 94 are at a different level from the bottoms of the drive bar 96 and the hinge elements 98, which define the bottom-most level of the module. Otherwise the module 90 is like the belt module 20 of FIGS. 1 and 2. Because the wear surfaces 94 of the wear pads 92, 93 are indented upward from the bottom-most level 100 of the module 90 as shown in FIG. 10, a conveyor belt constructed of the modules 90 forms a longitudinal slot 102 in which wear strips 104 are received. The downward extension of the drive bars 96 and the hinge elements 98′ bounding the wear pads 92, 93 past their indented wear surfaces 94 limits lateral wander of the conveyor belt by contact with the sides of the wear strips 104.

FIGS. 11 and 12 show two examples of wear indicators built into wear pads. In FIG. 11 a wear pad 106 has an internal layer 108 of a different color than the original outer wear surface 110. As the wear surface 110 wears, the internal layer of a different color becomes visible to indicate wear of the wear pad 106. In FIG. 12 a wear surface 112 is interrupted by grooves 114 that are elongated in the direction of belt travel 54. Slightly raised portions 116 of the base of the grooves serve as wear indicators like those in tire treads. As the wear surface 112 wears, the distance from the top of the wear indicators 116 to the worn wear surface decreases so that wear can be identified, and corrective action taken.

Another version of a belt module with a different outside edge is shown in FIGS. 13A and 13B. The module 120 is shown as an edge module with a wear pad 122 at an outer side 124 and suitable for constructing a bricklaid conveyor belt. But a wider module with a similar outer side at the other side, with or without interior wear pads, could be made for constructing non-bricklaid belts having a single module forming each belt row. The module 120 has first and second hinge elements 28, 29 and a drive bar 38 like the module of FIG. 2. The wear pad 122 has a slot 128 extending at an angle from the wear pad's wear surface 126 along an inner wall 129 of the wear pad for a rod-removal tool, such as a screwdriver, to access the end of a hinge rod and bend it away from a stop formed by the inner wall and toward the level of the wear surface so that the rod can be removed from the hinge elements. The inner wall 129, which presents a stop that is in line with and faces the line of first hinge elements 28, prevents the hinge rod from working its way out of the line of hinge elements during operation of the conveyor belt. The lateral extent and the area of the wear surface of the wear pad 122 are greater than those of the hinge elements 28, 29.

A belt module 130 with another version of a wear pad 132 at an outer side 134 is shown in FIGS. 14A and 14B. The wear pad's wear surface at the bottom of the module 130 has a lateral extent and an area greater than those of first and second hinge elements 28, 29. The wear pad 132 tapers away from the wear surface 136 along a ramp 138 in line with and facing the aligned first hinge elements 28. The ramp 138 is shown as concavely curved, but could also be flat. The ramp 138 provides a slide surface along which the end of a hinge rod can slide when the rod is pushed out through the hinge elements during manual removal. Like the module of FIGS. 13A and 13B, the belt module 130 can be a narrow edge module as shown or it can be a wider module with similar wear pads 132 at both outer sides. 

1. A conveyor belt module comprising: a module body extending in length from a first end to a second end, in width from a first side to a second side, and in thickness from a top side to a bottom side; a plurality of first hinge elements spaced apart laterally along the first end of the module body; a plurality of second hinge elements spaced apart laterally along the second end of the module body; drive faces extending laterally along the bottom side of the module body; one or more wear pads on the bottom side of the module body laterally offset from the drive faces; wherein the wear pads each have a wear surface at the bottom side; and wherein the area of the wear surface of each of the wear pads is greater than the area of any of the first and second hinge elements at the bottom side.
 2. A conveyor belt module as claimed in claim 1 wherein the one or more wear pads include a first solid wear pad at the first side of the module body and a second solid wear pad at the second side of the module body.
 3. A conveyor belt module as claimed in claim 1 wherein at least one of the wear pads includes a pad hinge element at the first end of the module body that forms a continuation of the wear surface of the wear pad and whose lateral extent is at least as wide as the lateral extent of the wear pad.
 4. A conveyor belt module as claimed in claim 1 wherein the drive faces are formed on laterally elongated drive bars that extend to the level of the wear surfaces at the bottom side of the module body.
 5. A conveyor belt module as claimed in claim 1 wherein the drive faces are formed on elongated drive bars that extend laterally from one of the wear pads to another of the wear pads.
 6. A conveyor belt module as claimed in claim 1 wherein the one or more wear pads are detachable from the module body.
 7. A conveyor belt module as claimed in claim 1 wherein a portion of the wear pads including the wear surface is made of a wear-resistant material and the rest of the module body is made of a different material.
 8. (canceled)
 9. A conveyor belt module as claimed in claim 1 wherein a portion of the wear pads including the wear surface includes a wear indicator that indicates wear of the wear surface.
 10. A conveyor belt module as claimed in claim 9 wherein the wear surface includes one or more grooves and the wear indicator comprises a raised portion of the base of the grooves.
 11. A conveyor belt module as claimed in claim 9 wherein the wear indicator comprises a layer of the wear pad interior of the wear surface that differs in color from the wear surface when not worn.
 12. A conveyor belt module as claimed in claim 1 wherein the wear surface of the wear pads is a closed surface.
 13. A conveyor belt module as claimed in claim 1 wherein the wear surfaces of the wear pads define the bottom-most level of the bottom side of the module body.
 14. A conveyor belt module as claimed in claim 1 wherein the wear surfaces of the wear pads are indented upward from the bottom-most level of the bottom side of the module body.
 15. (canceled)
 16. A conveyor belt module as claimed in claim 1 wherein one of the wear pads forms the first side of the conveyor belt module and has an inner wall forming a stop in line with and facing the first hinge elements.
 17. A conveyor belt module as claimed in claim 1 wherein one of the wear pads forms the first side of the conveyor belt module and has a ramp in line with and facing the first hinge elements and extending to the wear surface of the wear pad.
 18. A conveyor belt module as claimed in claim 1 wherein the lateral extent of the wear surface of each of the wear pads is greater than the lateral extent of any of the first and second hinge elements at the bottom side.
 19. (canceled)
 20. (canceled)
 21. A conveyor belt module comprising: a module body extending in length from a first end to a second end, in width from a first side to a second side, and in thickness from a top side to a bottom side; a plurality of first hinge elements spaced apart laterally along the first end of the module body; a plurality of second hinge elements spaced apart laterally along the second end of the module body; drive faces extending laterally along the bottom side of the module body; a plurality of wear pads on the bottom side of the module body laterally offset from the drive faces; wherein the wear pads each have a wear surface at the bottom side made of a different material from the rest of the module body.
 22. A conveyor comprising: a modular conveyor belt comprising a series of rows of one or more belt modules hingedly connected end to end at hinge joints between consecutive rows; wherein at least some of the rows include: drive faces extending laterally along a bottom side of the modular conveyor belt; a plurality of wear pads on the bottom side of the modular conveyor belt laterally offset from the drive faces; wherein the wear pads each have a wear surface at the bottom side of the modular conveyor belt; an upper carryway including a plurality of wearstrips spaced apart across the width of the carryway and extending linearly along the length of the carryway to support the modular conveyor belt; a drive element engaging the drive faces to drive the modular conveyor belt in a direction of belt travel along the carryway; wherein the wear pads on the bottom side of the modular conveyor belt are arranged in columns aligned with the wearstrips so that the wear surfaces ride on the wearstrips as the modular conveyor belt is driven in the direction of belt travel.
 23. A conveyor as claimed in claim 22 wherein the drive faces are formed on drive bars that are elongated in a direction perpendicular to the direction of belt travel and that extend to the bottom-most level of the bottom side of the modular conveyor belt.
 24. A conveyor as claimed in claim 22 wherein at least some of the rows have recessed regions on the bottom side adjacent the drive faces to receive the teeth of sprockets, wherein the recessed regions are bounded by end walls on the sides of the wear pads to limit lateral wander of the modular conveyor belt relative to an axially fixed sprocket.
 25. A conveyor as claimed in claim 22 wherein every row includes a plurality of the wear pads.
 26. A conveyor as claimed in claim 22 wherein the carryway wearstrips include outer wearstrips disposed along outer sides of the carryway and wherein the columns of wear pads on the modular conveyor belt include outer columns of wear pads whose wear surfaces ride on the outer wearstrips.
 27. A conveyor as claimed in claim 22 wherein each of the rows of belt modules comprises: first hinge elements spaced apart along first ends of the row and second hinge elements spaced apart along opposite second ends of the row; a pad hinge element at the first end of the row on one or more of the wear pads that forms a continuation of the wear surface.
 28. A conveyor as claimed in claim 27 wherein the area of the pad hinge element and the wear pad is greater than the area of any of the first hinge elements at the bottom side of the conveyor belt.
 29. A conveyor as claimed in claim 22 wherein the plurality of wear pads have guides extending downward on opposite sides of the wear surfaces that cooperate with the wearstrips to limit lateral wander of the conveyor belt on the carryway.
 30. A conveyor as claimed in claim 22 wherein each of the rows of belt modules comprises: first hinge elements spaced apart along first ends of the row and second hinge elements spaced apart along opposite second ends of the row; hinge rods extending through the interleaved first and second hinge elements of consecutive rows to connect consecutive rows together at the hinge; wherein each row of belt modules has wear pads forming outer sides of the conveyor belt.
 31. A conveyor belt module as claimed in claim 30 wherein the wear pads forming the outer sides of the conveyor belt each have a ramp in line with and facing the interleaved first and second hinge elements and extending to the wear surface of the wear pad to provide a sliding surface along which the hinge rod can be slid during removal from the hinge joint.
 32. A conveyor as claimed in claim 30 wherein the wear pads forming the outer sides of the conveyor belt each have an inner wall forming a stop in line with and facing the interleaved first and second hinge elements to prevent the hinge rod connecting the interleaved first and second hinge elements from working its way out of the hinge joint during operation of the conveyor.
 33. A conveyor as claimed in claim 32 wherein the wear pads forming the outer sides of the conveyor belt each have a slot extending from the wear surface of the wear pad along the inner wall for a removal tool to access the hinge rod. 